Chrome-plated bodyside molding for vehicle and method of making same

ABSTRACT

A multiple piece bodyside molding includes a cover piece connected to a base piece. The cover is formed in a manner and shape so that it may be chrome-plated while reducing the likelihood of bath/tank contamination during the chrome-plating process. Subsequent to being chrome-plated, the cover is connected to the base so as to form the resulting bodyside molding. The cover may be attached to the base via ultrasonic welding, vibration welding, snap-on connectors, or via heat-deforming or extension tabs in different embodiments of the invention.

This is a divisional of U.S. patent application Ser. No. 09/547,758,filed Apr. 12, 2000, which is a continuation-in-part of U.S. patentapplication Ser. No. 09/497,547, filed Feb. 3, 2000, the entire contentof which is hereby incorporated by reference in this application.

FIELD OF THE INVENTION

This invention relates to a bodyside molding for a wheeled vehicle suchas a car, sport utility vehicle, pick-up truck, or the like. Moreparticularly, this invention relates to a chrome-plated bodyside moldingand a method of making the same.

BACKGROUND OF THE INVENTION

Decorative and protective bodyside moldings formed at least in part fromthermoplastic materials are known in the art. Bodyside moldings protect,e.g., vehicle doors, and provide an aesthetically-pleasing appearance.Such moldings may be formed by injection molding and/or extrusionprocesses.

To form bodyside moldings by an extrusion process, generally one or morecontinuous, pliable, thermoplastic melt streams from suitable extrusiondyes are introduced into a forming tool which molds the melt stream(s)into a continuous extrusion having a desirable cross-sectional shape.Bodyside moldings are then cut from the continuous extrusion after theextrusion has sufficiently cooled. In one such process, a base layermelt stream is co-extruded along with an upper “show” surface layerhaving a desirable, aesthetically-pleasing appearance. The show surfacematerial may be of various materials suitable for the extrusion process,including Mylar, chrome or a show thermoplastic graded material.

FIG. 1 illustrates a representative vehicle 3 including decorativebodyside moldings 5 thereon. Each of components 5 a, 5 b, 5 c, 5 d and 5e, mounted on respective body portions of the vehicle, represents abodyside molding. Specifically, bodyside molding part 5 a is mounted onfront door 7, bodyside molding part 5 b is mounted on rear door 9,bodyside molding part 5 c is mounted on the fender rearwardly of thefront wheel well, and bodyside molding parts 5 d and 5 e are mounted onthe corner panel, forwardly and rearwardly, respectively, of the rearwheel opening of the vehicle.

FIGS. 2-3 illustrate a conventional bodyside molding, including moldingbody 9 having a hollowed interior, bolt 11, bolt mounting section 13,and seating body 15. As illustrated in FIG. 3, this bodyside molding isto be attached to vehicle 17 by way of bolts 11. As discussed in U.S.Pat. No. 5,639,522 (hereby incorporated herein by reference in itsentirety), the bodyside molding of FIGS. 2-3 is manufactured utilizing ahollow injection molding process.

Because bodyside moldings are designed to be aesthetically pleasing tothe eye, it is often desired to chrome-plate such moldings. It is knownto manufacture hollow one-piece chrome-plated bodyside moldings using agas-assisted injection molding process as follows. Initially, a flowablematerial such as TPO (polyolefinic thermoplastic resin) is injected intoa dye of an injection molding apparatus. Thereafter, a gas pin isinserted into the material within the dye cavity so as to allow gas(e.g., nitrogen) to be shot via the gas pin into a central portion ofthe material. The gas causes the flowable material to proceed/moveoutwardly within the dye against the edges thereof so as to form ahollowed-out piece. The gas pin is thereafter removed from the piece.Upon cooling and removal from the dye, the result is a bodyside moldingcomponent. However, this bodyside molding component has a hole oraperture defined therein due to the gas pin which had been insertedthrough a portion thereof in order to allow the pressurized gas to beintroduced.

The molding (including the hole therein) is then processed throughnumerous liquid/metal baths in order to chrome-plate the same. Forexample, the molding may first be dipped into an acid bath to prepareits surface to accept metal to be applied in a subsequent bath(s). Afterremoval from the acid bath, the molding is rinsed in a bath andthereafter dipped into an electroplating bath such as a copper or nickelbath. After removal from this copper or nickel bath, rinsing may againoccur in another bath, with the molding thereafter being dipped in achrome bath for electroplating the molding body with chrome. In short, aplurality of baths are utilized during the chrome plating process, withthe bodyside molding being moved from one bath to the next in serialfashion as the process progresses.

Unfortunately, the hole in the molding due to the gas pin describedabove is problematic. This hole tends to collect materials from thedifferent baths used in the electroplating process (e.g.liquid/chemicals from a bath can either collect in the hole itself orseep into the hollow interior of the body through the hole) whichultimately can lead to bath(s) contamination. For example, the hole maycollect acid from the acid bath. Upon removal from the acid bath, acidtherefrom is located in the hole itself and/or within the hollowinterior (i.e., cavity) of the molding. The rinsing process may thus notbe able to effectively remove all/most traces of the acid from the holeand/or cavity of the molding. As a result, when the molding issubsequently placed into another bath during the chrome plating process(e.g., a nickel bath, copper bath, and/or chrome bath), contaminatesfrom earlier bath(s) may make their way thereinto causing bathcontamination. In other words, later baths or tanks in theelectroplating process may become contaminated due to the tendency ofthe hole-inclusive molding to collect and transport materials from onebath to the next during the process.

It is apparent from the above that there exists a need in the art for abodyside molding which may be manufactured in a manner such that thelikelihood of bath/tank contamination is reduced during thechrome-plating process.

This invention will now be described with respect to certain embodimentsthereof, accompanied by certain illustrations.

SUMMARY OF THE INVENTION

An object of this invention is to provide a two-piece bodyside moldingwhich may be electro-plated in a manner so as to reduce the likelihoodof bath/tank contamination during an electroplating (e.g. chromeplating) process.

Another object of this invention is to provide a two-piece bodysidemolding, wherein one of the two pieces is chrome plated and the other ofthe two pieces is not chrome plated.

Another object of this invention is to provide a two-piece bodysidemolding including a cover piece and a base piece, wherein the coverpiece is chrome plated and the base piece is hidden from view by theplated cover piece.

Another object of this invention is to provide a two-piece bodysidemolding including a cover piece and a base piece, wherein the coverpiece is chrome plated before being affixed or connected to the basepiece. In certain embodiments, the cover piece is shaped in a manner soas to reduce the likelihood of bath contamination during the chromeplating thereof.

In certain embodiment of this invention, the chrome plated cover piecemay be attached or connected to the non-chrome-plated base piece viavibration welding, via heat deformation of heat stakes or tabs describedbelow, via a snap-fit design, via sonic welding, or in any othersuitable manner.

Another object of this invention is to fulfill any or all of theabove-listed objects.

Generally speaking, this invention fulfills any or all of the abovedescribed objects/needs by providing a bodyside molding to be attachedto a vehicle, the bodyside molding comprising:

a base having first and second spaced apart apertures defined therein;

a chrome plated cover including first and second sidewalls between whicha channel is defined; and

wherein an end of said first sidewall is connected to a first portion ofsaid base and an end of said second sidewall is connected to a secondportion of said base.

This invention further fulfills any or all of the above describedobjects/needs by providing a method of making a bodyside molding for avehicle, the method comprising the steps of:

forming a cover piece;

forming a base piece so as to include at least first and second spacedapart apertures defined therein;

plating or coating at least a portion of the cover piece;

inserting first and second end portions of the plated or coated coverpiece into the first and second apertures of the base, respectively;

heating at least portions of the first and second end portions whichextend through the first and second apertures, respectively; and

deforming heated portions of the first and second end portions whichextend through the first and second apertures, respectively, so as toconnect the cover piece to the base piece.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of an automobile including conventionalbodyside moldings thereon.

FIG. 2 is a perspective view of a conventional hollowed-out bodysidemolding.

FIG. 3 is an end cross-sectional view of the conventional bodysidemolding of FIG. 2 affixed to a vehicle.

FIG. 4 is an end cross-sectional view of a two-piece bodyside moldingaccording to an embodiment of this invention.

FIG. 5 is a flow chart illustrating steps taken during the manufactureof the two-piece bodyside molding of FIG. 4.

FIG. 6 is a top plan view of a base of the FIG. 4 molding according to afirst embodiment of this invention.

FIG. 7 is a top plan view of a base of the FIG. 4 molding according to asecond embodiment of this invention.

FIG. 8 is an end cross-sectional view of a two-piece bodyside moldingaccording to an embodiment of this invention, where the cover isattached or connected to the base via welding (e.g., sonic or vibrationwelding).

DETAILED DESCRIPTION OF CERTAIN EMBODIMENTS OF THIS INVENTION

Referring now more particularly to the accompanying drawings in whichlike reference numerals indicate like parts throughout the severalviews.

Certain embodiments of this invention relate to a bodyside molding whichis at least partially electroplated (e.g., chrome plated). The moldingmay be placed on the exterior of a vehicle for aesthetic purposes. Anybodyside molding herein may be positioned on a vehicle in any of thelocations illustrated in FIG. 1, or on any vehicle at any other suitablelocation where a bodyside molding is desired. Moreover, it is noted thatthe phrase(s) “chrome plated” and “chrome plating” as used herein refersto both actual chrome plating as well as any other material which may beapplied that resembles chrome in appearance.

FIG. 4 is an end cross-sectional view of bodyside molding 21 accordingto an embodiment of this invention. Bodyside molding 21 includeselongated cover 23 connected to elongated base 25. Cover 23 may beapproximately U-shaped (as in FIG. 4), V-shaped, or square shapedaccording to different embodiments of this invention, so as to definechannel 26 between opposing cover sidewalls 28 and 30 as illustrated inFIG. 4. Base 25 is at least partially planar in shape, including upperand lower major surfaces, in certain embodiments of this invention. Asshown in FIG. 4, base 25 may be formed so as to include a thickerportion 36 upon which tape assembly 27 is to be mounted. Thicker baseportion 36 may be defined by angled steps extending upwardly from theirrespective intersections 38 with thinner base portions.

As for cover 23, respective ends of sidewalls 28, 30 include outertongs/tabs 34 and inner tongs/tabs 35 integrally formed with the rest ofthe cover, as illustrated in FIG. 4. Inner tongs/tabs 35 extend throughcorresponding apertures or holes 33 defined in base 25 in order toconnect the cover to the base. Outer tongs 34 serve to hide base 25(which need not be chromed plated) from view after the molding 21 hasbeen affixed to a wheeled vehicle.

Thermoplastic cover 23 is connected to thermoplastic base 25 by innertongs/tabs 35. After tongs/tabs 35 are inserted through respectiveapertures 33 in base 25, the distal ends of the tongs/tabs 35 whichprotrude/extend through these apertures are heated and deformed (e.g.,mushroomed) up against the bottom of base 25. After cooling of theheated portions of tongs/tabs 35, the tongs/tabs 35 are locked orotherwise affixed in place adjacent the underside of the base. Thus,while FIG. 4 illustrates outer tongs/tabs 34 in the form in which theyexist both prior to and after cover 23 has been connected to base 25,this Figure shows inner tongs/tabs 35 in their respective forms prior toheating (i.e. after heating, the inner tongs may be mushroomed upagainst the underside of the base). In certain embodiments of thisinvention, adjacent tabs 34 and 35 are approximately parallel to oneanother at the end of each sidewall 28, 30, as illustrated in FIG. 4,prior to heating and deformation of inner tabs 35. Following heating anddeformation of at least inner tabs 35, the entireties of tabs 35 are nolonger approximately parallel with adjacent outer tabs 34, althoughportions of tabs 35 within apertures 33 may remain approximatelyparallel to adjacent portions of outer tabs 34.

Bodyside molding 21 may be affixed to a vehicle by way of double-sidedtape system 27 which initially includes layers 29 and 31. Tape layer 31may comprise acrylic foam tape attached to the lower major surface ofbase 25. Generally speaking, one side of tape layer 31 is fastened tobase 25 at the site of manufacture, with release layer 29 being providedon the remaining outwardly-facing side of tape 31. Release layer 29 isleft in place and removed just prior to attachment of molding 21 to anassembled piece of a vehicle. In other words, after shipment of themolding to an automotive assembly location, release layer 29 is removedso that tape layer 31 can be used to adhere molding 21 to desiredvehicle component(s) 17.

An exemplary manner of manufacturing bodyside molding 21 will now bedescribed with reference to at least FIGS. 4 and 5. Initially, cover 23and base 25 are injection molded using separate injection molding dyesand respective dye cavities (steps 51 and 53). In preferred embodiments,cover 23 and base 25 are made of or include ABS(acrylonitrile-butadiene-styrene) or PC-ABS (mixture of polycarbonateand ABS). However, in alternative embodiments, cover 23 and base 25 mayinstead be made of or include TPO, polyethylene, polypropylene, surlyn,nylon, polycarbonate (PC), PVC, or the like. Moreover, while cover 23and base 25 are initially separately formed via injection molding inpreferred embodiments, they may instead be formed using separateextrusion techniques in other embodiments of this invention.

Base 25 is molded in a manner so as to include thru-holes 33 thereinwhich extend from one major surface through the body of the base to theother major surface thereof. Following its removal from its injectionmolding cavity, base 25 need not be chrome plated (although it may be incertain non-preferred embodiments).

As for cover 23, after removal from its injection molding dye, cover 23is in the form illustrated in FIG. 4 (absent attachment to the base).Prior to being attached to the base, cover 23 is chrome plated (e.g. byan electro-plating technique as described above which includes multiplebaths or tanks utilized in series with one another) (step 55). Elongatednon-hollow cover 23 is shaped so that it does not include any cavitiesor apertures which tend to collect liquid which can contaminatesubsequent baths in the chrome-plating process. Cover 23 is elongated inthe direction extending in and out of the paper relative to FIG. 4 in amanner similar to the molding in FIG. 2.

After cover 23 has been chrome plated (step 55), inner tongs/tabs 35thereof are inserted through apertures/holes 33 of non-chrome platedbase 25 (step 57). Simultaneously, outer tongs 34 extend downwardlyaround a peripheral portion/edge of base 25 so as to cover and hide fromview outer edges of the base. Portions of inner tongs/tabs 35 whichextend through apertures/holes 33 are then heated (e.g., via hot airheated to a temperature of about 300-400° F., preferably about 350° F.)to a degree sufficient so that the heated portions of the tongs can bedeformed in a manner such that they mushroom onto or against a bottomsurface 41 of base 25 (steps 59 and 61). The mushroomed (i.e., at leastpartially flattened or otherwise deformed in a manner so as to contactthe bottom surface of the base) tong portions are then allowed to cool(step 63). After cooling, cover 23 is mechanically connected to base 25so as to form bodyside molding 21, as the mushroomed portions of tongs35 prevent these tongs from being pulled back through apertures 33.Thereafter, double sided tape system 27 may be adhered to a bottomsurface of base 25 (step 65). When it is desired to adhere the moldingto a vehicle, release layer 29 is removed so that tape layer 31 can beused to adhere molding 21 to the vehicle (step 67). Chrome plated outertongs/tabs 34, in certain embodiments, are sufficiently long so thatthey hide non-chromed plated base 25 from view after the molding hasbeen adhered to the vehicle.

As shown in FIGS. 1-2, all bodyside moldings herein are elongated inshape in certain embodiments. Thus, in certain embodiments,apertures/holes 33 in the base may be elongated in shape so as toresemble thru-slots which extend a substantial portion of the length ofthe molding as shown in FIG. 6. In such embodiments, tongs/tabs 34, 35are likewise elongated in shape so as to also extend a substantialportion of the length of the molding (i.e., a single elongated tong(s)34, 35 is provided on each side of the cover extending substantially theentire length of the cover).

However, in other embodiments of this invention, a plurality ofseparate, distinct, and spaced-apart apertures/holes 33 may be providedalong each side of the base as shown in FIG. 7. In such embodimentswhere the apertures are spaced apart as in FIG. 7, outer tongs 34 mayremain elongated so as to extend substantially the entire length of thecover, while a plurality of spaced apart inner connecting tongs/tabs 35are provided on each side of the cover so as to correspond with thespaced apart apertures 33 shown in FIG. 7.

In embodiments discussed above, a tape system is described for attachingthe bodyside molding to a vehicle. However, in other embodiments of thisinvention, the molding may be attached to a vehicle in other manners(e.g., via fasteners, via clips, via W-base clips which may snap intoplace, or the like).

In embodiments discussed above, the ends of the cover are insertedthrough the base and thereafter heated in order to attach the cover tothe base. However, in other embodiments of this invention, the cover mayinstead by glued or otherwise adhered to the base, or alternatively thecover may be sonic welded to the base without tabs. In otherembodiments, the cover may be sonic welded to the base with or withouttabs.

For example, FIG. 8 illustrates an embodiment wherein the cover isconnected or attached to the base via ultrasonic or vibration welding.Tabs 35 are not necessary in this embodiment; and neither are apertures33 in the base. Respective ends of the cover are welded to at least anupper surface of the base in this embodiment.

While the invention has been described in connection with what ispresently considered to be the most practical and preferred embodiment,it is to be understood that the invention is not to be limited to thedisclosed embodiment, but on the contrary, is intended to cover variousmodifications and equivalent arrangements included within the spirit andscope of the appended claims. For example, while exemplary embodimentsdiscussed above refer to chrome plating of the cover piece, it will beunderstood by those skilled in the art that any other type of plating orcoating may instead be applied to the cover piece via any type ofplating/coating process.

What is claimed is:
 1. A bodyside molding to be attached to a vehicle,the bodyside molding comprising: an elongated base; an electroplatedcover including first and second portions between which an elongatedchannel is defined; and wherein an end of said first portion of saidcover is welded to a first portion of said base and an end of saidsecond portion of said cover is welded to a second portion of said base.2. The bodyside molding of claim 1, wherein said first and secondportions comprise first and second sidewalls, respectively, and whereinsaid cover is approximately U-shaped with the trough of the “U” beinglocated in spaced relation from said base.
 3. The body side molding ofclaim 1, wherein said end of said first portion of said cover isvibration welded to said first portion of said base, and said end ofsaid second portion of said cover is vibration welded to said secondportion of said base.